FEATURE u Cover Story
Figure 2: Asset health insights on a converged IT/OT network
deployment of smart sensors to monitor asset health. The second growth area is the increased use of artificial intelligence and advanced analytics to transform asset health data into actionable insights for predictive maintenance and create new service-based, predictive maintenance business model opportunities. Growth in new condition monitoring
deployments will range across multiple industries, including: Waste and wastewater treatment; Manufacturing; Paper and pulp; Food and beverage; Pharmaceutical; Metal and mining; Energy; Oil and gas installations. Within these industries, condition monitoring applications are expanding beyond the traditional rotating equipment applications (pumps, compressors, and fans) to new applications in CNC machines, machine tools, encoders, conveyor belts, robotics, and instruments (see Figure 1).
EXISTING COMMUNICATIONS CHALLENGES Connectivity from smart sensors to higher level management systems has been one of the key challenges for condition monitoring applications. To date, condition monitoring applications have used wired or wireless connectivity solutions depending on the end
application requirements. Wireless connectivity solutions have advantages in terms of ease of deployment but are often limited in terms of bandwidth and/or battery life. Wired connectivity solutions are sometimes limited in data bandwidth, and long distances in harsh industrial environments are not always supported and often require a separate cable for power.
Existing Industrial Ethernet solutions based on 100BASE-TX/10BASE-T provide high data bandwidth up to 100Mb and power over a Cat-5 or Cat-6e cable with PoE but are limited to 100m distance and don’t support hazardous area use cases as they are high power solutions.
Condition monitoring applications require
support for potentially remote sensors that require robust communication over a long distance where the sensor node is in a space and power constrained IP66/IP67 enclosure due to the harsh industrial environment it is deployed in.
These constrained sensor node applications need a low power, high data bandwidth communications solution that delivers both power and data on a low cost, easy to install cable with a small cable connector to the sensor node.
NEW CONNECTIVITY SOLUTIONS WITH SINGLE PAIR ETHERNET New single pair Ethernet (SPE) physical layer standards developed by the IEEE are offering new connectivity solutions for communicating asset health insights for condition monitoring applications. 10BASE-T1L is a new Ethernet physical layer standard (IEEE 802.3cg-2019) that was approved by the IEEE on 7 November 2019. It will dramatically change the automation industry by significantly improving operational efficiency through seamless Ethernet connectivity to field-level assets. 10BASE-T1L solves the challenges that, to date, have limited the use of Ethernet to the field assets. These challenges include power, bandwidth,
cabling, distance, data islands, and Intrinsically Safe Zone 0 (hazardous areas) applications. By solving these challenges for both brownfield upgrades and new greenfield installations, 10BASE-T1L will enable new asset health insights that were previously unavailable and seamlessly communicate them to the control layer and to the cloud/private server. These new insights will awaken new possibilities for data analysis, operational insights, and productivity improvements through a converged Ethernet network from the field assets to the cloud or private server (see Figure 2).
Figure 3: Field asset, smart sensor connectivity with a 10BASE-T1L PHY
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